Hyundai Elantra Neos / Hyundai i30. Manual - part 16

BODY DIMENSIONS

BD-17

Tooling hole                               (ø25)

Tooling and paint drain hole
                                                  (ø20)

Tooling hole                               (ø25)

Tooling hole                               (ø25)

Rear suspension mounting hole
                                                 (ø21)

Tooling hole                               (ø11)

Cross member mounting hole
                                                  (ø19)

BFDBD6137

BFDBD6136B

BFDBD6140

BFDBD6141

BFDBD6136

A,A'

C,C'

E,E'

BFDBD6138

F,F'

G,G'

BFDBD6139

H,H'

J,J'

Body Panel Repair

Procedure

BP

BACK COMPLETE PANEL AND REAR
FLOOR SIDE MEMBER

.............................. BP - 55

REMOVAL ........................................................ BP - 56
INSTALLATION ................................................. BP - 58

FRONT AND REAR DOOR OUTER
PANELS

............................................................. BP - 62

REMOVAL ........................................................ BP - 63
INSTALLATION ................................................. BP - 63

REPLACING BODY PANELS

CODES FOR REMOVING AND
INSTALLING BODY PANELS ........................... BP - 2

NOTES WHEN WELDING BODY

REMOVING SPOT WELDED AREA ................ BP - 3
INSTALLING A NEW BODY FRAME ................ BP - 5
DETERMINING A WELDING METHOD ........... BP - 5
SPOT WELDING .............................................. BP - 5
CARBON ARC WELDING ............................... BP - 6
REPLACING BODY PANEL

REMOVAL ................................................... BP - 7
PREPARATION FOR INSTALLATION ........ BP - 9
INSTALLATION ........................................... BP - 10

FENDER APRON PANEL

........................... BP - 12

REMOVAL ........................................................ BP - 13
INSTALLATION ................................................. BP - 15

FRONT SIDE MEMBER

............................... BP - 18

REMOVAL ........................................................ BP - 19
INSTALLATION ................................................. BP - 20

FRONT PILLAR

.............................................. BP - 22

REMOVAL ........................................................ BP - 23
INSTALLATION ................................................. BP - 27

SIDE SILL PANEL

.......................................... BP - 31

REMOVAL ........................................................ BP - 31
INSTALLATION ................................................. BP - 33

CENTER PILLAR

........................................... BP - 34

REMOVAL ........................................................ BP - 35
INSTALLATION ................................................. BP - 42

QUARTER PANEL

......................................... BP - 46

REMOVAL ........................................................ BP - 47
INSTALLATION ................................................. BP - 48

LOWER QUARTER PANEL

....................... BP - 51

REMOVAL ........................................................ BP - 52
INSTALLATION ................................................. BP - 53

BP-2

BODY  PANEL REPAIR PROCEDURE

REPLACING BODY PANELS

CODES FOR REMOVING AND INSTALLING BODY PANELS

BVQBP6001A

Location for cut and assembly

Rough cutting location

20~30 mm

(0.8~1.2 in.) 

20~30 mm

(0.8~1.2 in.) 

BODY PANEL REPAIR PROCEDURE

BP-3

NOTES WHEN WELDING BODY

REMOVING SPOT WELDED AREA

Most body parts are spot welded. In order to remove the damaged area, it is best to remove the spot welded area from the
body frame using a spot cutter or candle type edge drill bit.
Do not use a drill bit with a tapered edge. Center punch middle of spot weld to insure the entire spot weld will be removed.

BVQBP6002

1.  Spot cutter

1.  Drill(candle type edge)

1.  Drill(taper edge)

2.

2.

2.

3.

3.

3.

Correct

Correct

Not correct